New Delhi Aug 24 PTI Indian scientists have for the first time repaired aero-engine components through emerging additive manufacturing or 3D printing technique that can significantly reduce repair costs and overhaul time the Department of Science and Technology DST said on TuesdayThey indigenously made powders suitable for the additive manufacturing process called the Directed Energy Deposition processNickel-based superalloys are widely used in aero-engine components Despite having exceptional properties they are prone to damage due to extreme operational conditions Manufacturing defects during the casting or machining process are other major causes of rejection and tons of such unused components are scrapped due to minor defects it saidA team of scientists from the International Advanced Research Centre for Powder Metallurgy and New Materials ARCI an autonomous RD Centre of the DST indigenously developed powders suitable for additive manufacturing using inert gas atomizer available at the ARCI by melting unused scrap materialUtilising this the ARCI is developing the laser-DED process for the repair of aero-engine components made of Ni-based superalloysFurthermore the ARCI team developed a technology to refurbish pinion housing assembly critical component in helicopters used for power transmission to the main fan by machining out the damaged layer and rebuilding it using laser cladding process followed by final machiningLaser cladding and laser-DED both processes are the same In general for two-dimensional deposition surface coating the term laser cladding is used and for the manufacture of three-dimensional parts the term laser-DED is used A patent has been filed for the same the DST saidA post-clad heat treatment method was also designed to minimise microstructural inhomogeneity and ensure minimal substrate properties variationThese laser-clad repaired prototypes were found to be free from distortion and exhibited excellent performanceThe team has also developed repair and refurbishment technologies for other industrial sectors such as refurbishing diesel engine cylinder heads made of grey cast iron and refurbishing shafts used in the refinery This work has been published in the journal Transactions of The Indian Institute of MetalsThus the impact of repair and refurbishment technology developed by the ARCI can be best realised in the aerospace sector due to expensive materials manufacturing costs and stringent quality checks PTI PR IJT